Low Density Frostings and Methods

ABSTRACT

The invention relates to low density ready-to-spread frosting compositions and related methods. “Icing” and ‘frosting’ are terms conventionally used to identify spreadable, semi-solid confectionery products that are applied as toppings to sweeten and decorate baked goods such as cakes, breads, cookies, and the like. Generally, icings and frostings can be categorized into several basic types depending in part on whether a particular product contains fat (generally shortening) or not, and whether or not the product is aerated.

RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 14/508,439, filedOct. 7, 2014, which is a continuation of U.S. Ser. No. 14/191,854, filedFeb. 27, 2014, which is a continuation of International No.PCT/US2014/015368, filed on Feb. 7, 2014, entitled “LOW DENSITYFROSTINGS AND METHODS,” which applications are herein incorporated byreference in their entireties.

FIELD OF THE INVENTION

The invention relates to low density frosting compositions and relatedmethods, preferred compositions being low in trans fats and containingnon-hydrogenated palm-oil based fat.

BACKGROUND

“Icing” and “frosting” are terms conventionally used to identifyspreadable, semi-solid confectionery products that are applied astoppings to sweeten and decorate baked goods such as cakes, breads,cookies, and the like. Generally, icings and frostings can becategorized into several basic types depending in part on whether aparticular product contains fat (generally shortening) or not, andwhether or not the product is aerated. Types include royal icings,fluffy frostings, cream icings, and aerated creamy frostings. Thepresence of a fat affects the emulsion characteristics of an icing orfrosting. “Icing” is sometimes used to refer to an unaeratedcomposition, while “frosting” tends to refer to an aerated product.

Within this broad category of sweetened spreadable toppings or fillingsare ready-to-spread (“RTS”) frostings, which, as the name indicates, arefully prepared frostings that can be spread onto a food product withoutthe need for preparation steps by a consumer-purchaser. RTS frostingsare a popular consumer food product due to the convenience of beingfully prepared. RTS frostings presented for sale in a fully prepared andoptionally aerated state. They can be packaged and stored unopened atroom temperature for extended times (a one-year shelf life target istypical), or stored after opening at refrigerator temperatures forrelatively shorter times. RTS frostings can be applied directly out of aproduct container to a cake or other baked good without mixing or anyother preparation step. RTS frostings are thus formulated so as to beusable without the addition of ingredients or other further preparationsteps by the consumer.

Desired organoleptic and performance properties for RTS frostingsinclude a smooth texture, desired consistency, spreadability withoutflowing or running, resistance to syneresis or weeping of the frostingin an unopened container, resistance to syneresis or weeping betweencake layers upon overnight storage, and stability. A density suitablefor a low-density, whipped RTS frosting can be from about 0.75 to about0.95 grams per cubic centimeter. For these low density products,stability requires good resistance to air cell collapse or coalescenceupon extended shelf storage or during stirring or other use by aconsumer.

Fat-containing RTS frostings, as is typical with many fat-containingprepared food products, are likely or certain to contain a hydrogenatedfat ingredient, and, therefore, to include trans fats. “Trans” fats areisomers of naturally occurring unsaturated fatty acids that aretypically created during hydrogenation processes of many fat ingredientsof frostings, including previous RTS and low density RTS frostings.Partially and fully-hydrogenated fats have been used in processed foodsfor many years, meaning that many commercial processed food productformulations contain trans fats. Recently trans fats have becomedisfavored. There is a current strong interest for fat compositions thatcan be useful substitutes for trans-containing hydrogenated fats incommercial food product formulations, i.e., useful fat ingredients thatcontain low levels of trans fats or are free of trans fats.

While a strong interest lies in removing trans fats from food products,including RTS frostings and low density RTS frostings, the challenge ofre-formulating previous commercial products to avoid trans fats isdaunting, especially if consumer expectations are already in place,which is true for low density RTS frostings. The food industry wouldexpect high demand for a low density frosting that includes a low or avery low amount of trans fats, e.g., zero trans fats, but such a productwould be less successful if the change in frosting ingredients orprocessing necessary to reduce the level of trans fats caused changes tothe product that would upset consumer's expectations relative to pastproducts.

Thus, although the use of low trans fat in food products is a generalgoal, replacing a fat ingredient of a food product such as a low-densityRTS frosting, which is well established with a consuming public, is animposing challenge. Replacing any ingredient of an establishedcommercial food product must be done in a manner that does not have anoverwhelming affect on taste and non-taste properties of the product. Inthe case of low density frosting, these challenges are at least as greatas with other consumer food products due to consumer expectations that alow density frosting exhibit desired flavor, density, texture,appearance, and stability.

SUMMARY

The invention relates to low density frostings that can be soldcommercially, that exhibit useful and desirable organoleptic andstability properties. The low density frostings can be preparedcommercially to include desirable or highly desirable taste, texture,mouthfeel, appearance, viscosity, spreadability, and storage stabilityproperties.

The low density frostings are prepared to contain fat ingredients thathave a low trans fat content, yet still allow processing by aeration toform a low density frosting, preferably one that is stable over extendedstorage of weeks or months at a low density. Fat of the frosting caninclude two separate components. A first fat component isnon-hydrogenated low trans fat-containing palm oil-based shortening. Thesecond fat component is a crystal-enhancing fat component such as a roomtemperature solid fully-hydrogenated fat ingredient or a roomtemperature solid partially-hydrogenated fat ingredient.

Non-hydrogenated low trans fat-containing palm oil-based shorteningmaterials have been found to be not useful when included alone as a fatingredient (combined with other frosting ingredients) of an aerated lowdensity frosting formulation. The non-hydrogenated palm oil-basedshortenings, when combined with other frosting ingredients such assugar, water, emulsifier, etc., have been found to not possess thephysical properties necessary to form and maintain a low density aeratedfrosting structure. When these non-hydrogenated palm oil-basedshortening materials are combined with the other frosting ingredientsand processed to produce aeration, the result is typically a non-aeratedliquid that does not exhibit a low density or other properties of a lowdensity whipped aerated frosting.

According to the present description, Applicant has identified that lowtrans fat-containing non-hydrogenated palm oil-based shorteningmaterials can be made to form an aerated low density frosting bycombining the non-hydrogenated palm oil-based shortening with another,harder fat ingredient, referred to as a crystal-enhancing fat component.The combined fat ingredients can be aerated to form a low densityfrosting, even where the non-hydrogenated palm oil-based shorteningcannot. The combined fat ingredients have also been found to exhibit arate of crystallization that is faster than a rate of crystallization ofthe non-hydrogenated palm oil-based shortening alone. Exampleembodiments of the low density frosting are sufficiently stable to passthe “Stir-Down test” described herein.

In one aspect, the invention relates to a low density frosting thatincludes: from 50 to 85 weight percent sweetening agent based on totalweight frosting; from 15 to 30 weight percent total fat ingredientsbased on total weight frosting, the total fat ingredients include a) amajor amount of non-hydrogenated palm oil-based shortening ingredient,and b) up to about 25 weight percent crystal-enhancing fat ingredient,based on weight total fat ingredients; and from 10 to 20 weight percentwater based on total weight frosting. The frosting has a density in arange from 0.75 to 0.95 grams per cubic centimeter.

In another aspect the invention relates to a low density frosting thatincludes: from 50 to 85 weight percent sweetening agent based on totalweight frosting; from 15 to 30 weight percent total fat ingredientsbased on total weight frosting, the total fat ingredients comprising amajor amount of non-hydrogenated palm oil-based shortening ingredient;and from 10 to 20 weight percent water based on total weight frosting.The frosting has a density in a range from 0.75 to 0.95 grams per cubiccentimeter. The total fat ingredients exhibit a rate of crystallizationprofile having a percent solid fat measurement of at least 20 percent at2.5 minutes.

In another aspect the invention relates to a low density frosting thatincludes: from 50 to 85 weight percent sweetening agent based on totalweight frosting; from 15 to 30 weight percent total fat ingredientsbased on total weight frosting, the total fat ingredients comprising: a)a major amount of non-hydrogenated palm oil-based shortening ingredient,and b) up to about 25 weight percent room temperature solidpartially-hydrogenated fat, based on weight total fat ingredients in thefrosting; and from 10 to 20 weight percent water based on total weightfrosting. The frosting has a density in a range from 0.75 to 0.95 gramsper cubic centimeter.

In yet another aspect the invention relates to a low density frostingthat includes: from 50 to 85 weight percent sweetening agent based ontotal weight frosting; from 15 to 30 weight percent total fatingredients based on total weight frosting, the total fat ingredientscomprising at least 90 weight percent of a blend of non-hydrogenatedpalm oil-based shortening ingredient and room temperature solidpartially-hydrogenated fat; and from 10 to 20 weight percent water basedon total weight frosting. The frosting has a density in a range from0.75 to 0.95 grams per cubic centimeter. The total fat ingredientsexhibit a rate of crystallization profile having a percent solid fatmeasurement of at least 20 percent at 2.5 minutes.

In another aspect the invention relates to a fat composition thatincludes: a major amount of non-hydrogenated palm oil-based shorteningingredient, and up to about 25 weight percent room temperature solidcrystal-enhancing fat ingredient, based on total weight fat composition.The fat composition exhibits a rate of crystallization profile having apercent solid fat measurement of at least 20 percent at 2.5 minutes.

In another aspect the invention relates to a fat composition thatincludes: a major amount of non-hydrogenated palm oil-based shorteningingredient; and up to about 25 weight percent room temperature solidpartially-hydrogenated fat, based on weight total fat composition. Thefat composition exhibits a rate of crystallization profile having apercent solid fat measurement of at least 20 percent at 2.5 minutes.

In yet another aspect the invention relates to a method for making a lowdensity frosting. The method includes combining frosting ingredientsthat include: from 50 to 85 weight percent sweetening agent based ontotal weight frosting; from 15 to 30 weight percent total fatingredients based on total weight frosting, the total fat ingredientscomprising: a) a major amount of non-hydrogenated palm oil-basedshortening ingredient, and b) up to about 25 weight percentcrystal-enhancing fat ingredient, based on weight total fat ingredients;and from 10 to 20 weight percent water based on total weight frosting.The combined frosting ingredients are homogenized to form a homogenizedfrosting base having a density of about 1.1 to 1.3 grams per cubiccentimeter. The homogenized ingredients are cooled to a temperature offrom about 60 to about 70 F within a residence time of about 2 to 30seconds to form a cooled frosting base. The cooled frosting base ismixed with inert. The gas and cooled frosting base is aerated whilecooling to form a low density frosting having a density of about 0.75 to0.95 grams per cubic centimeter.

Throughout the specification and claims all percentages used herein arein weight percentages and are based on the total weight of the lowdensity frosting composition, unless otherwise indicated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1, 2, and 3 show Rate of Crystallization information for fatsamples.

FIG. 4 shows a schematic of a process as described.

DETAILED DESCRIPTION

The following description relates to low density frostings made ofingredients that include a low-trans fat non-hydrogenated palm oil-basedshortening, a crystallization-enhancing fat ingredient, sugar, water,and other ingredients generally at low or minor amounts.

The frostings have a low density, meaning that they are aerated and havea density that is below 0.95, 0.94, preferably below about 0.9 or belowabout 0.87 cubic centimeters per gram. Preferred low density frostingsalso have a stable structure of air bubbles supported by a matrix, thematrix being made of the frosting materials (fat, sugar, etc.) and beingsufficiently stable that the low density frosting can be prepared,stored, transported, and presented for commercial sale while maintaininga low density. Upon use by a consumer, the density of preferred frostingembodiments does not unduly increase, such as upon a consumer opening apackage of the frosting and stirring the frosting within the package.(See the Stir-Down Test described herein.)

Embodiments of the described low density frostings can exhibit otheruseful frosting properties such as flavor, texture, mouthfeel (e.g.,non-waxy feel), viscosity, and spreadability properties that allow forsale as a consumer frosting product. Preferably, a low density frostingas described can contain a low amount of trans fat, such as less than 2,1, 0.5, 0.4, 0.2, or less than 0.1 weight percent trans fat based on atotal weight frosting.

Exemplary low density frostings can have any useful water activity.Water activity is a measure of the amount of chemically available waterin a frosting, i.e., water that is not bound, or “free.” A lower wateractivity of a frosting means that the frosting has a lower amount offree water in a frosting, which reduces the propensity for the frostingto dry out and harden. Also, a lower water activity of a frostingimproves the ability of the frosting to contain solid particulates suchas chocolate chips, without degrading the particulates. And a lowerwater activity reduces the potential for microbial growth in a frosting,which allows for reduction or elimination of preservatives. Withoutlimiting the present disclosure or claims, examples of water activity ofthe described low density frostings can be in a range from about 0.7 toabout 0.85, e.g., from about 0.75 to about 0.82.

A described low density frosting can include a total amount of fatingredients, referred to as “total fat ingredients” of the frosting, asubstantial portion of which is non-hydrogenated palm oil-basedshortening ingredient (or “palm oil-based shortening” for short).Another portion of the total fat ingredients is crystal-enhancing fatingredient, which is a fat ingredient that is (among other things) solidat room temperature, e.g., up to about 20 or 25 weight percent based onthe weight of total fat ingredients of the frosting. As used herein theterm “total fat ingredients” refers only to ingredients understood to befat or oil ingredients, generally meaning ingredients that have a highor very high level of tri-glycerides; the term does not refer to otheringredients that include concentrated levels non-tri-glyceride fattyacids or fatty acid residues such as ingredients that include a highconcentration of mono-glycerides or di-glycerides, especially suchingredients that are known as emulsifiers or dispersants.

Various palm oil-based shortenings are known. They have been identifiedas having taste and organoleptic properties desired in a frosting, e.g.,have been found to exhibit desired performance in terms of taste,mouthfeel, or texture, when combined with other ingredients to produce afrosting. They also provide a low trans fatty acid nutritional profile.But these fat ingredients if used alone as the sole fat ingredient in afrosting do not exhibit processing properties that allow them to beprocessed by aeration, with other frosting ingredients, into a lowdensity frosting. The present Applicant has now identified that when aminor amount of crystal-enhancing fat ingredient is combined with thepalm oil-based shortening, the blend of these two fat materials canfunction as total fat ingredients of a frosting that are capable ofbeing processed with other frosting ingredients into an aerated lowdensity frosting, preferably one that is stable as specified in theStir-Down Test described herein.

The palm oil-based shortening is non-hydrogenated, meaning that it doesnot substantially contain fat material that has been processed by amethod of hydrogenation. Hydrogenation is a known method used toincrease a level of saturation of a fat material, and that also is knownto produce trans fatty acid in the fat material. The palm oil-basedshortening used in a frosting as described herein is made substantiallyof one or a combination of fat ingredients that are not hydrogenated,meaning not partially-hydrogenated and not fully-hydrogenated. Forexample, the palm oil-based shortening can contain at least 90, 95, 99,or 100 weight percent non-hydrogenated fat materials, especiallynon-hydrogenated palm-oil based fat materials. A portion of thenon-hydrogenated palm oil-based shortening may optionally befractionated or interesterified to effect desired or advantageousmechanical properties such as plasticity, melt point, etc. The palmoil-based shortening preferably excludes any substantial amount (e.g.,contains less than 1 percent, less than 0.5, 0.2, or 0.1 weight percent)of hydrogenated, partially-hydrogenated, or fully-hydrogenated fatmaterial.

The palm oil-based shortening includes a major amount of fat derivedfrom palm oil, which is known to include high naturally occurring levelsof saturated fatty acids and low levels of trans fatty acids. The palmoil-based shortening may be what is referred to as a pure oil or a wholeoil (e.g., whole palm oil), e.g., the palm oil-based shortening may beentirely (e.g., 100 percent) whole palm oil. Other embodiments of thepalm oil-based shortening can be a portion of whole palm oil combinedwith a portion of fractionated or interesterified fat (especially palmoil). Fractionated palm oils are known, and are prepared by knownmethods of fractionation (e.g., fractionated palm oil, fractionated palmkernel oil), using crystallization and separation processes, to obtainmore solid (stearin) fractions eliminate more liquid (olein) fractions.Interesterified fats (including interesterified palm oil or palm oilfractions) are also known and can be prepared by known methods ofinteresterification whereby fatty acid residues of tri-glycerides areremoved and re-combined, i.e., exchanged between glyceride molecules ina manner that affects one or more physical properties of the fat such asmelting point or solid fat content.

Palm oil is to be distinguished from palm kernel oil. Both palm kerneloil and palm oil are obtained from the same plant, but from differentparts. Palm kernel oil is obtained by expression of palm kernels. Palmoil is obtained from the husks rather than the seed nut. Palm oil ischaracterized by a red color resulting from a high carotene level. Also,palm oil is characterized by high levels of palmitic and oleic acidswhereas palm kernel oil is a lauric oil similar to coconut oil, havinglittle palmitic or oleic acid. Naturally occurring whole palm oil isfluid at room temperature in contrast to palm kernel oil.

Embodiments of the palm oil-based shortening can include a majority ofor a high or very high level of non-hydrogenated whole palm oil.Exemplary embodiments of palm oil-based shortenings can contain at least50 weight percent, at least 70, 80, 90, 95, 99 or more weight percentnon-hydrogenated whole palm oil. Optionally, some or all of the wholepalm oil may be interesterified or otherwise modified other than byhydrogenation.

Certain embodiments of palm oil-based shortenings include a blend ofnon-hydrogenated whole palm oil, and a non-hydrogenated stearin fractionof palm oil. Such two-part blends of whole palm oil and palm stearin maycontain any useful amount of each of these two fat materials, such asfrom about 50 to about 95 weight percent whole palm oil and from about 5to about 50 weight percent palm stearin fraction; from 70 to about 90weight percent whole palm oil and from about 10 to about 30 weightpercent palm stearin fraction; or from about 75 or 80 to about 90 weightpercent whole palm oil and from about 10 to about 20 or 25 weightpercent palm stearin fraction. Optionally, some or all of the whole palmoil or the palm stearin, or both, may be interesterified or otherwisemodified, except by hydrogenation.

While not necessarily preferred, a palm oil-based shortening used in afrosting as described may also contain a low or minor amount of non-palmoil-based fat or other non-fat ingredients. Examples of non-palmoil-based fat ingredients include known non-palm oil fats and theirderivatives (e.g., fractionated, hydrogenated, modified), includingnon-tropical and tropical fats. Examples include oils obtained fromsoybean, rapeseed (canola), sunflower, peanut, hazelnut, walnut,cottonseed, olive, corn, grapeseed, rice bran, sesame, safflower,linseed/flax, oat, wheat germ, copra oil, cottonseed oil, palm kerneloil, coconut oil, rice bran oil, palm kernel oil (e.g., fractionatedpalm kernel oil), and the like. Certain more specific examples includelow linolenic soybean oil, high oleic canola oil, and high oleic soybeanoil. Others include triglyceride oils that are derived frommicroorganisms, animals (e.g., lard, tallow, butter), and plants. Thesemay optionally be natural, processed by interesterification,hydrogenation, or fractionation, genetically modified, or traitenhanced.

A non-palm oil-based fat or non-fat ingredient may be present in a palmoil-based shortening ingredient in an amount that does not substantiallydeteriorate from important properties of the palm oil-based shorteningor the finished low density frosting, such as taste, mouthfeel, texture,viscosity, Rate of Crystallization, spreadability, processability to alow density form, and stability. A preferred amount of such non-palmoil-based fat or non-fat ingredient may be an amount that does notexceed about 10, 5, 2, or 1 weight percent of the palm oil-basedshortening. Most preferably, the palm oil-based shortening can containless than 1 or less than 0.5 weigh percent of such non palm oil-basedfat or non-fat ingredient.

A palm oil-based shortening may optionally and preferably be plastic, orcapable of being formed into a plastic, e.g., by a known method such asvotation. As used herein, the term “plastic” in reference to a palmoil-based shortening means a solid, non-fluid, non-pourable andnon-pumpable shortening (fat) at room temperature of 70 degrees F. (21degrees C.).

The palm oil-based shortening can also be characterized as exhibitingone or more of other various mechanical traits found to be useful forpreparing the described frosting. One well-known trait forcharacterizing a fat composition is Solid Fat Content (SFC). SFC isdetermined for a fat sample by detecting the NMR signal from both liquidand solid components in the fat sample, or by detecting the change inthe liquid signal as it is displaced by solid. AOCS methods fordetermining SFC include AOCS Cd 16b-93 revised in 2000 (Direct Method)and AOCS Cd 16-81 revised in 2000 (Indirect Method). Using SFC, amelting curve or SFC profile can be created by measuring SFC for a fatsample at several different temperatures and then plotting the SFCmeasurements as a function of temperature.

Exemplary palm oil-based shortenings can exhibit an SFC profile thatfalls within the following ranges of solid fat (percent) in a shorteningat certain temperatures: from about 47 to 63 percent at 10 degrees C.,from about 20 to 40 percent at 20 degrees C., from about 4 to 21 percentat 30 degrees C., up to about 12 percent at 40 degrees C.; alternatelyfrom about 49 to 57 percent at 10 degrees C., from about 23 to 39percent at 20 degrees C., from about 6 to 19 percent at 30 degrees C.,up to about 10 percent at 40 degrees C.

Another property that is useful to characterize a fat composition isMettler Drop Point (MDP). Examples of palm oil-based shortenings usefulin a frosting as described can exhibit a Mettler Drop Point (MDP) thatranges from about 90 degrees Fahrenheit to about 130 F, e.g., from about95 to about 120 degrees F., or from about 100 to about 115 degrees F.

Iodine value (I.V.) is another trait useful to characterize fatcompositions. Certain exemplary palm oil-based shortenings useful infrostings as described can have an iodine value of about 44 to 57, e.g.,from about 48 to 53.

Preferred palm oil-based shortening can be beta prime crystal formtending fat materials, meaning fat materials that include a solid phasethat is substantially in a beta prime phase crystalline form (i.e., atleast 50% of the solids). Descriptions of such beta prime phase tendingshortenings and their rapid cooling methods of preparation are found inU.S. Pat. No. 2,801,177 (issued Jun. 30, 1957 to E. S. Lutton and U.S.Pat. No. 3,253,928 (issued May 31, 1966 to Bedenk et al), which areincorporated herein by reference.

The palm oil-based shortening can also be characterized based on a Rateof Crystallization (ROC) profile. Rate of Crystallization of a fat is ameasure of the amount of crystallized solids (solid fat) contained inthe fat over a period of time at which the temperature of the sample isreduced under controlled conditions. The palm oil-based shorteningshould exhibit a ROC profile that allows crystals to form in the totalfat ingredients of a frosting, during processing, especially duringearly processing of frosting ingredients to produce a low densityfrosting.

A Rate of Crystallization of a palm oil-based shortening that may beuseful with other ingredients to prepare a low density frosting asdescribed, may exhibit a ROC profile as follows: at least about 15percent solids at 2.5 minutes, at least about 21 percent solids at 5minutes, at least about 28 percent solids at 7.5 minutes, and a leastabout 30 percent solids at 10 minutes. An alternate or preferred ROCprofile of the palm oil-based shortening may be: from about 15 to about25 percent solids at 2.5 minutes, from about 22 to about 35 percentsolids at 5 minutes, from about 30 to about 40 percent solids at 7.5minutes, from about 32 to about 42 percent solids at 10 minutes.

Useful non-hydrogenated palm oil-based shortenings that includesubstantially entirely whole palm oil, fractionated palm oil, or blendsthereof, are commercially known and available. Such products can rangefrom commodity whole palm oil (IV ˜50-56, MPD ˜35-39 C) to blends ofwhole palm with fractionated palm oil components such as palm stearin(IV ˜14-40, MDP ˜44-52C).

Examples of commercially available non-hydrogenated palm oil-basedshortening ingredients include those that are whole palm oil (100percent palm oil), and others that are a mixture of whole palm oil andpalm stearine (e.g., from 90:10, 80:20, or 60:40 palm oil:palm stearin).Some examples of the latter mixtures may exhibit properties that includethe following: SFC (@10 Deg C.: 53-61; @20 Deg C: 30-38; @30 Deg C:10-18; @40 Deg C: <8). (IV ˜48-52, MDP ˜39-44.5 C). Some examples of theformer whole palm oils may exhibit an SFC profile as follows: @10 Deg C:47-57; @20 Deg C: 21-25; @30 Deg C: 7-14; @40 Deg C: <6).

The presently described frosting compositions can contain any usefulamount of the non-hydrogenated palm oil-based shortening ingredient,meaning an amount to form a low density frosting as described,preferably a low density frosting that exhibits stability as measured bythe Stir-Down Test described herein. Exemplary amounts can be from about15 to about 30 weight percent, preferably about 20 to about 28 weightpercent of the described palm oil-based shortening based on total weightfrosting.

The described low density frosting also includes a crystal-enhancing fatingredient that improves or allows for processing of the total fatingredients with other frosting ingredients to form a low densityfrosting, especially one having good long term stability. The describednon-hydrogenated palm oil-based shortening ingredients have been foundto exhibit certain organoleptic properties desirable in a frostingproduct. But as identified by the Applicant, these same palm oil-basedshortenings are not by themselves as a sole fat ingredient capable ofproviding a frosting ingredient composition that can be processed into alow density frosting. When the described non-hydrogenated palm oil-basedshortening ingredients have been included as the only fat ingredient ina frosting formulation, the resultant frosting ingredients have beenfound to be not capable of being processed by aeration to produce a lowdensity frosting composition, especially one that is stable as measuredby the Stir-Down Test.

The present invention includes the discovery that a small amount ofanother type of fat ingredient that is inter alia solid at roomtemperature, can be added to non-hydrogenated palm oil-based shorteningingredients and the resultant blend, when used as the total fatingredients of the frosting, is capable of being combined with otherfrosting ingredients and processed into a low density frosting. Thefrosting ingredients form a low density composition during processing,and the low density frosting is sufficiently stable to be stored andtransported for commercial sale, and can preferably be capable ofpassing the Stir-Down Test described herein.

According to the described frostings a small amount of crystal-enhancingfat ingredient can be combined with the palm oil-based shortening toproduce total fat ingredients of the frosting that can be included withother frosting ingredients to produce a useful low density frosting,preferably with good stability. The crystal-enhancing fat ingredient isa fat that is solid at room temperature, and that can be combined withthe palm oil-based shortening ingredient to produce total fatingredients that can be processed into a low density frosting,especially one that exhibits stability as measured by the Stir-DownTest. If frosting ingredients contain only the palm oil-based shorteningas described (i.e., total fat ingredients are only the palm oil-basedshortening, e.g., whole palm oil or a combination of whole palm oil andstearin fraction), the frosting ingredients have been found to not becapable of being processed into a low density frosting. But when a smallamount of the crystal-enhancing fat ingredient (as described herein) isused in combination with the palm oil-based shortening (i.e., total fatingredients are the palm oil-based shortening and the crystal-enhancingfat ingredient), blends of these two fat ingredients have been found tobe capable of being processed into a low density frosting that ispreferably stable as measured by the Stir-Down Test.

In brief, and without being bound by theory, a crystal-enhancing fatingredient has been found to improve the ability of a composition offrosting ingredients to be processed into an aerated low density form,and to increase the stability of the formed low density frosting. Thecrystal-enhancing fat ingredient may function by increasing the rate oramount of crystals that are present in a frosting during processing,especially during an early stage of processing (within a first two orthree minutes of processing by mixing at a reduced temperature). Theearly-stage crystals improve formation of an aerated low densityfrosting by proving solid structure around air cells. A low densityfrosting structurally includes a supportive three-dimensional matrixformed about thousands of tiny air cells. Crystals in the matrixfunction as a solid supportive structure of the matrix that surroundsand supports the air cells. A matrix made more stable by solid crystalscan inhibit or prevent the otherwise natural coalescence of the aircells. Solid crystals formed during early processing allow rapidformation and strengthening of the three-dimensional matrix. Afterformation the crystals continue to support, strengthen, and maintain thematrix, sustaining the low density aerated form over extended storageperiods.

The ability of a fat material to form crystals, especially during earlystages of processing into a low density frosting, can be assessed as theRate of Crystallization (ROC) of the fat material. And, as described,the Rate of Crystallization of total fat ingredients of a frostingformulation has been found to relate to the ability of frostingingredients that contain the total fat ingredients to be processed intoa low density frosting. Rates of Crystallization of any particular palmoil-based shortening blended with crystal-enhancing fat ingredient havebeen identified to be higher than the Rate of Crystallization of thatpalm oil-based shortening absent the crystal-enhancing fat ingredient.In addition, while the lower-ROC palm oil-based shortening may beincapable of being processed into a low density frosting, blends of thesame palm oil-based shortening combined with crystal-enhancing fatingredient, wherein the blends exhibit ROC higher than the palmoil-based shortening alone, have been processed into useful andpreferably highly stable low density frostings.

Accordingly, a useful amount of crystal-enhancing fat ingredient in alow density frosting, or in a portion of total fat ingredients of a lowdensity frosting, can be an amount that allows frosting ingredients thatinclude the total fat ingredients (with a blend of palm oil-basedshortening ingredient and crystal-enhancing fat ingredient) to beprocessed to form a low density frosting. Preferred amounts are amountsthat allow the frosting ingredients to be formed into a low densityfrosting that is stable as measured by the Stir-Down Test. The amountand useful ranges may depend on the specific crystal-enhancing fat usedin the frosting. Useful amounts may be expressed in terms relative to anamount of total fat ingredients of a low density frosting, relative toan amount of total frosting ingredients, or as an amount that results intotal fat ingredients that exhibit a desired ROC profile (see below)effective to form a low density frosting.

Relative to total fat ingredients a useful amount of crystal-enhancingfat ingredient may be an amount of up to about 25 weight percentcrystal-enhancing fat ingredient based on total fat ingredients, e.g.,from about 5 to about 22 weight percent, or from about 7 to about 20weight percent crystal-enhancing fat ingredient based on the weight ofthe total fat ingredients.

Relative to total frosting ingredients, the amount of crystal-enhancingfat ingredient may be up to about 5 weight percent crystal-enhancing fatingredient based on total frosting ingredients, e.g., from about 0.5 toabout 4 weight percent, or from about 1 to about 3 weight percent basedon total fat ingredients.

Considered based on function, a useful amount of crystal-enhancing fatingredient can be any amount that, when used in combination with a palmoil-based shortening, provides total fat ingredients that have a Rate ofCrystallization that allows the total fat ingredients to be formed intoa low density frosting when combined with other frosting ingredients. Auseful Rate of Crystallization of total fat ingredients may be one thatreflects a functional improvement of the total fat ingredients relativeto the ROC of the palm oil-based shortening of the total fat ingredientsby itself. For example, a Rate of Crystallization of total fatingredients should be more than insignificantly higher than the Rate ofCrystallization of the palm oil-based shortening component alone. An ROCprofile is obtained by taking a series of percent solids measurements ofa fat sample over a period of time, such as regularly and periodicallyover a 10 minute period, e.g., at about every 30 seconds. To beconsidered more than an insignificant amount higher than a Rate ofCrystallization of a palm oil-based shortening ingredient (alone) oftotal fat ingredients, percent solids measurements of an ROC profile ofthe total fat ingredients should exceed the percent solids measurementsof an ROC profile of the palm oil-based shortening ingredient (alone)over substantially an entire 10 minute ROC profile, by an amount of atleast 5 percent, preferably by at least 10, 15, 20, 25, or 30 percent(for example, a 20 percent increase in percent solids exists if thepercent solids of the shortening ingredient is 10 and the percent solidsof the total fat ingredients is 12). According to certain embodiments oftotal fat ingredients, a solid percent measurement of total fatingredients can exceed the solid percent measurement of the palmoil-based shortening (alone) by at least 10, 20, or 25 percent, at leastat a measurement taken at 2.5 minutes; preferably a solid percentmeasurement of total fat ingredients can also exceed the solid percentmeasurement of the palm oil-based shortening (alone) by at least 5, 10,15, 20, or 25 percent, at one or more measurement taken at 5, 7.5, and10 minutes.

Another way to characterize a useful Rate of Crystallization of totalfat ingredients is in terms that are independent of a Rate ofCrystallization of the palm oil-based shortening (alone) of the totalfat ingredients. For example, a Rate of Crystallization of total fatingredients that may be useful to prepare a low density frosting asdescribed, may include a percent fat measurement of at least 20 percentsolids, e.g., 21 or 23 percent solids at 2.5 minutes. In certainembodiments the Rate of Crystallization may be expressed as a ROCprofile as follows: at least about 20 (e.g., from about 22 to about 35)percent solids at 2.5 minutes, at least about 30 (e.g., from about 32 toabout 50) percent solids at 5 minutes, at least about 35 (e.g., fromabout 39 to about 52) percent solids at 7.5 minutes, and at least about39 (e.g., from about 39 to about 55) percent solids at 10 minutes.

Examples of specific crystal-enhancing fat ingredients include fatingredients that are solid at room temperature, such as room temperaturesolid hydrogenated fats (either partially-hydrogenated orfully-hydrogenated), room temperature solid fractionated fats, roomtemperature solid interesterified fats, and the like. Examples of suchfat materials are known to contain a high percentage (e.g., at least 92,95, or 98 percent) of tri-glycerides that contain a significant amountof saturated fatty acid residues. Some may also contain a substantialamount of trans fatty acid residues, e.g., up to about 30, 40, or 50percent trans fats based on total weight crystal-enhancing fatingredient.

A crystal-enhancing fat ingredient may be a fat that is naturally solidat room temperature or that is naturally liquid at room temperature, andthat has been processed to be solid at room temperature, e.g., by one ormore of fractionation, interesterification, or hydrogenation(partially-hydrogenated or fully-hydrogenated). The crystal-enhancingfat ingredient may be a combination of two or more such materials.Examples of useful crystal-enhancing fat ingredients includefully-hydrogenated fats having a Mettler Drop Point (MDP) that rangesfrom about 120 F to about 150 F, e.g., from about 130 F to 148 F, orfrom about 136 F to 140 F, one single example being fully-hydrogenatedsoybean oil. Other examples of useful crystal-enhancing fat ingredientsinclude partially-hydrogenated fats having a Mettler Drop Point (MDP)that ranges from about 95 F to about 130 F, e.g., from about 100 F toabout 120 F, examples being partially-hydrogenated cottonseed oil,partially-hydrogenated soybean oil, and combinations ofpartially-hydrogenated cottonseed oil and partially-hydrogenated soybeanoil.

Exemplary crystal-enhancing fat ingredients can exhibit a useful SFCprofile, which may depend on the type of ingredient, such as whether thecrystal-enhancing fat ingredient is fully-hydrogenated orpartially-hydrogenated.

Examples of fully-hydrogenated crystal-enhancing fat ingredients canexhibit a SFC profile that falls within the following ranges of solidfat (percent) in a shortening at certain temperatures: from about 90 toabout 100 percent at 10 degrees C., from about 90 to about 100 percentat 20 degrees C., from about 70 to about 100 percent at 30 degrees C.,from about 60 to about 100 percent at 40 degrees C.; alternately fromabout 95 to about 100 percent at 10 degrees C., from about 85 to about100 percent at 20 degrees C., from about 75 to about 100 percent at 30degrees C., from about 65 to about 100 percent at 40 degrees C.; and,alternately from about 95 to about 100 percent at 10 degrees C., fromabout 90 to about 100 percent at 20 degrees C., from about 85 to about100 percent at 30 degrees C., from about 75 to about 100 percent at 40degrees C.

Examples of partially-hydrogenated crystal-enhancing fat ingredients canexhibit a SFC profile that falls within the following ranges of solidfat (percent) in a shortening at certain temperatures: from about 75 toabout 100 percent at 10 degrees C., from about 65 to about 90 percent at20 degrees C., from about 30 to about 55 percent at 30 degrees C., fromabout 0 to about 20 percent at 40 degrees C.; alternately from about 75to about 90 percent at 10 degrees C., from about 65 to about 85 percentat 20 degrees C., from about 35 to about 50 percent at 30 degrees C.,from about 5 to about 15 percent at 40 degrees C.; alternately fromabout 77 to about 85 percent at 10 degrees C., from about 67 to about 80percent at 20 degrees C., from about 35 to about 45 percent at 30degrees C., from about 7 to about 13 percent at 40 degrees C.

The crystal-enhancing fat ingredients can additionally or alternately becharacterized on Iodine Value, percent trans fat content, each of whichmay depend on the type of ingredient such as whether thecrystal-enhancing fat ingredient is fully-hydrogenated orpartially-hydrogenated. Examples of useful crystal-enhancing fatingredients include fully-hydrogenated fats (one single example beingfully-hydrogenated soybean oil) having an Iodine Value of not greaterthan 15, e.g., not greater than 10, or not greater than 5. Examples ofuseful crystal-enhancing fat ingredients include fully-hydrogenated fats(one single example being fully-hydrogenated soybean oil) having notgreater than 10 weight percent trans fat, e.g., less than 5 weightpercent trans fat or less than 2 weight percent trans fat based on totalweight crystal-enhancing fat ingredient. Examples of usefulcrystal-enhancing fat ingredients include partially-hydrogenated fats(examples including partially-hydrogenated cottonseed oil,partially-hydrogenated soybean oil, and combinations ofpartially-hydrogenated cottonseed oil and partially-hydrogenated soybeanoil) having an Iodine Value of not greater than 100, e.g., from about 10to about 100, from about 20 to about 90, or from about 30 to about 70.Examples of useful crystal-enhancing fat ingredients includepartially-hydrogenated fats (examples including partially-hydrogenatedcottonseed oil, partially-hydrogenated soybean oil, and combinations ofpartially-hydrogenated cottonseed oil and partially-hydrogenated soybeanoil) having not greater than 60 weight percent trans fat, e.g., fromabout 20 to about 60 weight percent trans fat, from about 20 to about 40weight percent trans fat, or from about 25 to about 35 weight percenttrans fat based on total weight crystal-enhancing fat ingredient.

A crystal-enhancing fat ingredient may be any oil or fat-basedingredient or derivative thereof that can exhibit a solid form a roomtemperature and that can be combined with a non-hydrogenated palmoil-based shortening to produce total fat ingredients that may becombined with other frosting ingredients to form a low density frostingas described, optionally and preferably a fat that combines with thepalm oil-based shortening to produce a blend of crystal-enhancing fatingredient and palm oil-based shortening that exhibits at least one ofthe desired ROC profiles described herein. Examples include fats derivedfrom non-tropical or tropical sources and processed to reduce a meltingpoint or desirably effect on or more other physical property for use asthe crystal-enhancing fat ingredient. Some specific examples includeroom temperature solid fat materials derived from palm, palm kernel,soybean, rapeseed (canola), sunflower, peanut, hazelnut, walnut,cottonseed, olive, corn, grapeseed, rice bran, sesame, safflower,linseed/flax, oat, wheat germ, copra oil, cottonseed oil, coconut oil,rice bran oil, palm kernel oil (e.g., fractionated palm kernel oil), andthe like. Certain more specific examples include room temperature solidfat materials derived from low linolenic soybean oil, high oleic canolaoil, and high oleic soybean oil. Others include room temperature solidfat materials derived from fats that include triglycerides derived frommicroorganisms, animals (e.g., lard, tallow, butter), and plants. Any ofthese may optionally be natural, processed by interesterification,hydrogenation, or fractionation, genetically modified, or traitenhanced.

Exemplary crystal-enhancing fat ingredients can be produced byhydrogenating (partially or fully, as desired) unsaturated fatty acidsthat are present in a natural, fractionated, modified, or otherwiseprocessed oil, to increase the amount of saturated fatty acids.Techniques for hydrogenation of oils are known and include, for example,reacting a base oil having unsaturated fatty acids with hydrogen gas inthe presence of a hydrogenation catalyst, for example, a supportednickel catalyst. The hydrogenated fat product may be partially orfully-hydrogenated. Representative hydrogenated room temperature solidfats useful as a crystal-enhancing fat ingredient include fully orpartially-hydrogenated soybean oil, fully or partially-hydrogenatedcottonseed oil, fully or partially-hydrogenated palm oil, fully orpartially-hydrogenated palm kernel oil, fully or partially-hydrogenatedcoconut oil, fully or partially-hydrogenated canola oil, and mixturesthereof.

The combination of the palm oil-based shortening and thecrystal-enhancing fat ingredient can preferably be all of the fatingredients in a frosting, i.e., the total fat ingredients of afrosting. For example, total fat ingredients can contain at least 90,95, or 99 weight percent palm oil-based shortening and crystal-enhancingfat ingredient. On the other hand, some small amount of other fats canalso be allowed in the frosting, i.e., in the total fat ingredients,provided that the amount is sufficiently small to allow formation of adesired low density frosting. To the extent that total fat ingredientsinclude a fat material in addition to the palm oil-based shortening andthe crystal-enhancing fat ingredient, the amount should be small orminor, e.g., less than 10 weight percent of the total fat ingredients,preferably less than 10, 5, 3, 2, or 1 weight percent of the total fatingredients.

Total fat ingredients of a frosting can exhibit a Mettler Drop Point(MDP) that ranges from about 100 F to 131 F, e.g., from about 104 F to122 F.

Exemplary total fat ingredients can exhibit an SFC profile that fallswithin the following ranges of solid fat (percent) in a shortening atcertain temperatures: from about 55 to about 70 percent at 50 degreesF., from about 25 to about 55 percent at 70 degrees F., from about 18 toabout 40 percent at 80 degrees F., from about 8 to about 30 percent at90 degrees F., and from about 0 to about 20 percent at 100 degrees F.;alternately from about 56 to about 67 percent at 50 degrees F., fromabout 30 to about 50 percent at 70 degrees F., from about 19 to about 37percent at 80 degrees F., from about 10 to about 26 percent at 90degrees F., and from about 2 to about 17 percent at 100 degrees F.

Total fat ingredients can be low in trans fats, e.g., may contain lessthan about 10 weight percent, less than 5 weight percent, or less than 2or 1 weight percent trans fat based on the weight of the total fatingredient.

A nutritive carbohydrate sweetening agent or “sugar” is the principalsweetening ingredient in a low density frosting as described, and aprincipal ingredient overall. The sweetening agent provides bulk andbody to the frosting and contributes to organoleptic properties of thefrosting such as sweetness, texture, consistency, viscosity, density,and taste.

Useful as the sweetening ingredient are any of a variety of edibleoligosaccharides having one, two, or more saccharide groups includingfor example, sucrose, fructose, dextrose, maltose, lactose, galactose,sorbitol, and mixtures thereof. These sugars can be used in any of avariety of conventional forms, such as, for example, cane sugar, beetsugar, corn syrup, corn syrup solids, brown sugar, maple sugar, maplesyrup, honey, molasses, and invert sugar. Preferably, sweetening agentcan be selected from the group consisting of sucrose, fructose,dextrose, maltose, and mixtures thereof. More preferably, sweeteningagent can be a mixture of sucrose and corn syrup, which generally is amixture of dextrins, maltose, fructose, and dextrose. Most preferably,the sweetening agent can be sucrose, e.g., powdered sugar.

The amount of sweetening agent in a low density frosting can be adjustedwithin a desired range to achieve a desired sweetness level and suitableorganoleptic properties. Desired organoleptic properties can be similarprevious aerated cream icings or butter-cream frostings, e.g., smoothtexture, short consistency, spreadability without flowing or running,and a density of about 0.75 to 0.95 g/cc, more particularly from about0.75 to 0.9 g/cc or from 0.75 to 0.85 g/cc. Exemplary amounts ofsweetening agent in the low density frosting can be from about 50 toabout 85 weight percent, or from about 55 to about 80 weight percent,especially from about 58 to about 72 weight percent based on totalweight frosting.

In certain frosting embodiments, a sweetening agent can be a blend ofsucrose and corn syrup, which also functions as a plasticizer andhumectant. In such embodiments, sucrose can be included in an amount ina range from about 50 to 70 weight percent, e.g., from about 53 to about62 weight percent, based on total weight frosting. Corn syrup can beincluded in an amount in a range from about 2 to 20 weight percent ofthe frosting, such as from about 4 to about 12 weight percent based ontotal weight frosting. Higher syrup levels are especially useful forcocoa flavored products.

The low density frosting can also include emulsifier to providingdesired texture, a spreadable consistency, body, and a creamy mouthfeel. An emulsifier may also be useful to stabilize the low densityfrosting, provide freeze/thaw stability, increase viscosity, or preventicing breakdown due to moisture weeping.

Some emulsifiers, e.g., monoglycerides, have relatively higher meltingpoints compared to the fat ingredients. Consequently, as more emulsifieris added to the shortening to form an emulsified shortening, meltingpoint and hardness may increase. As an increased emulsifier levelhardens the shortening, blending with other frosting ingredients becomesmore difficult. Thus, a first portion of emulsifier may be preblendedwith a fat ingredient, and one or more additional portion may be addedto frosting ingredients in dry powder form or liquid form.

Certain useful emulsifiers include monoglycerides. A monoglyceride canaffect properties of fat ingredients of a frosting, such as by aidingdispersion of fat ingredients throughout the other frosting ingredients,e.g., sugar syrup. Certain examples of monoglyceride emulsifiers includemixtures of monoglycerides of higher fatty acids; e.g., a combination of75 to 80% oleic acid with the balance being linoleic acid and having aniodine value (“IV”) substantially less than 50. Monoglycerideingredients (e.g., distilled monoglyceride) will contain low levels ofother materials such as diglycerides or monoglycerides of other fattyacids or degrees of unsaturation. Mono- and diglyceride blends can beused if a monoglyceride fraction has desired iodine value and fatty acidchain length. Monoglycerides can be useful in any amount that can resultin a desired low density frosting as described, such as from 0.5 to 0.8weight percent monoglyceride ingredient based on total weigh frosting.

Other exemplary emulsifiers include esters of polyhydric alcohols(especially sorbitan esters) such as polyoxyethylene fatty acid estersof polyhydric alcohols, especially polyethoxylated esters of sorbitansuch as Polysorbate 60 (polyoxy-20-ethylene sorbitan stearate) andpolyoxyethylene sorbitan monostearate (e.g., Tween-60 and Tween-80),polyglycerol esters of higher fatty acids, Polysorbate 80 (i.e., apolyoxy-20-ethylene sorbitan monooleate), and mixtures thereof.Polysorbate 80 can be included in combination with polyglycerol ester.Preferred polyglycerol esters are selected from the group consisting oftriglycerol monostearate, decaglycerol monooleate, decaglycerolmonopalmitate, decaglycerol dipalmitate, hexaglycerol monostearate andmixtures thereof. Especially useful herein as a PGE is decaglyceroldipalmitate. Other suitable emulsifiers include unmodifiedmonoglycerides, mono and diglyceride blends, triglycerol monostearate,sorbitan esters, propylene glycol fatty acid esters, and lecithin.Exemplary useful high HLB emulsifiers include ethoxylatedmonoglycerides, polysorbates, ethoxylated sorbitans, decaglycerolesters, e.g., decaglycerol dipalmitate.

Emulsifier can be added one or a combination of frosting ingredientsdirectly, as a single ingredient, or in a variety of forms, such as acomponent of another ingredient such as a fat. The total amount ofemulsifier (e.g., a single emulsifier or a combination of emulsifiers)in a low density frosting can be any amount useful to produce a desiredfrosting. A total level of emulsifier can be selected to achieve lowdensity in combination with other frosting properties such as a creamy,rich mouth feel, smooth texture, a desired consistency, spreadability,viscosity, and desired density and stability. Exemplary amounts ofemulsifier can be from about 0.5 to about 5 weight percent, e.g., from0.5 to about 4 weight percent, based on total weight frosting.

The low density frosting can include a viscosity building ingredient toprovide desirable body, texture, and stability. Suitable examplesinclude hydrocolloids such as guar gum, locust bean gum, alginates,xanthan gum, agar-agar, gellan gum, gelatin, pectin and low-methoxylpectin and water soluble cellulose materials such as sodiumcarboxymethylcellulose, and methyl cellulose, microcrystalline celluloseand mixtures thereof. A specific example of a viscosity building ismoderate to high viscosity carboxymethylcellulose (7500 cps at 1%solution). The carboxymethylcellulose can be used at about 0.03 to 0.08weight percent, preferably about 0.04 to 0.07 weight percent (based ontotal weight frosting). A particular example is marketed as AVICEL,which is a mixture of microcrystalline cellulose and sodiumcarboxymethylcellulose, available from Food and Pharmaceutical ProductsDivision of FMC Corporation, Philadelphia, Pa.

The type and amount of viscosity agent can vary to provide desired endproduct attributes. Good results may be obtained when the frostingcontains from about 0.04 to about 3 weight percent viscosity agent,e.g., from about 0.15 to 0.2 weight percent, especially when theviscosity agents comprise a mixture of carboxymethylcellulose andxanthan gum.

The low density frosting can have a total moisture content ranging fromabout 10 to 20 weight percent, e.g., preferably about 11 to about 16weight percent or from about and more preferably about 13 to 15 weightpercent, based on total weight frosting. The moisture is supplied inpart by moisture associated with the syrup component, but primarily byadded water.

The low density frosting can optionally also include any of a variety ofadjuvant materials to modify the nutritional, organoleptic, flavor,color, or other properties of the frosting. In particular, the lowdensity frosting may include one or more fat replacer, e.g., sucrosepolyesters or hydrated colloidal protein dispersions (such as SIMPLESSEfat replacer, which is available from The NutraSweet Company). The lowdensity frosting optionally further include sugar replacers or bulkingagents such as polydextrose, low DE maltodextrins, or specially modifiedstarches. Purified polydextrose, which can be used to replace both sugarand fat, is disclosed in U.S. Pat. No. 4,622,233. If present, such fator sugar substitutes can each comprise about 0.1 to 15% of the presentcompositions, preferably less than about 12%.

Additionally, synthetic and natural flavorings or coloring agents can beincluded in a low density frosting as described. Exemplary flavorsinclude cream or cream cheese flavor, milk powder, chocolate, vanillaextract, vanilla powder, cocoa substitute, hazelnut, dutched cocoa,mint, lemon and mixtures thereof. The flavoring agents are preferablyused in amounts of about 0.01 to 3%. The coloring agents are preferablyused in amounts of about 0.01 to 0.05%. Also, flavor materials andparticulates such as fruit and fruit extracts, nuts, chips, and thelike, can be added to the frosting compositions as desired.

Other additives can be present in the low density frosting in minoramounts, e.g., less than about 1 weight percent, preferably less thanabout 0.5 weight percent, if desired. These include, for example: salt,whiteners, such as titanium dioxide, etc., mold inhibitors, such aspotassium sorbate, sorbic acid, dehydroacetic acid, sodium benzoate,etc., sequestering agents, acidulants, buffers, food acids,preservatives, antioxidants, such as butylated hydroxytoluene, butylatedhydroxyanisole, etc., vitamins, minerals, and the like.

The low density frosting can be prepared by methods that include stepsof combining ingredients, blending or mixing, aerating, heating,cooling, etc., examples of which steps and methods are known. Oneexample of a process of preparing a low density frosting is illustratedat FIG. 1.

Referring to FIG. 1, it shows a schematic process flow of an exemplarymethod 10. A first step is blending 12 of a combination of certainfrosting ingredients to form a uniform mixture by first mixing orblending together in any order sweetening agent (e.g., sugar) and water,fat ingredients, and optionally viscosity agent, emulsifier, and otheradditives, in such a manner as to achieve a uniform fluid blend of theseingredients. A ribbon blender is suitable to perform a blending step 12.

Blending step 12 can involve preblending substeps or ingredienthandling. For example, a combination (optionally pre-mixed) of heatedingredients can be added together into a blender or mixer, theingredients including emulsifier (15), molten shortening (e.g., palmoil-based shortening ingredients), other fats includingcrystal-enhancing fat ingredient, and monoglyceride. The palm oil-basedshortening ingredient can be added in a plastic or may be added to theribbon blender (12) in a heated melted form, e.g., at a temperature ofat least about 130 F, such as from about 130 to about 145 F (54 to 63 C)and optionally may be added as the final ingredient to the combination.Insufficiently heated frostings may permit some undesirablecrystallization of the fat ingredients. A similar process is shown atU.S. Pat. No. 5,529,800, the entire content of which is incorporatedherein by reference.

Blending step 12 can also include a preblending step 16, which preparesa preblend of minor ingredients 20 with water 18 to form a slurry. Theslurry formation allows for hydration of viscosity agent. The preblenddry mix 20 contains minor ingredients such as flavor, color, andemulsifier. The preblend can be mixed with water 18, for a useful amountof time such as about five minutes.

The preblended slurry and melted shortening, fat, and monoglycerideingredients form an emulsion upon blending (12). To the blendedemulsion, powdered sugar 22 is added and further mixing is conducted. Inpreferred variations, the blending step 12 can involve a period of highshear blending to break up and disperse the dry ingredients. Also. Inpreferred variations, the shortening ingredient is added last to themixture, after all other ingredients of this step.

During the mixing period (e.g., approximately five minutes), fatingredients dispersed in the product are cooled to about 95 F, at whichtemperature seeding and crystallization of up to about 5 weight percentof the total fat ingredients occurs. During blending step 12 the hardestfractions of the total fat ingredients (e.g., the crystal-enhancing fatingredient) begin to crystallize to “seed” the still liquid palmoil-based shortening ingredient.

The process 10 also includes a step of homogenizing 30 the blendobtained from step 12 to form a homogenized frosting composition orfrosting base. An example of a useful homogenizing step 30 can involve atwo-stage piston (e.g., 100 psi, 750 psi) homogenizer. Thehomogenization step can reduce the fat particle size to a few microns indiameter. The homogenized base is warmed by about 2 degrees C. by thework of the homogenization step.

A next step (40) can be to cool the homogenized frosting base to atemperature of about 15.5 to about 26.2 C (about 60 to about 80 F). Acooling step can be useful to convert a molten shortening in thehomogenized base into plastic shortening in situ after it has beendispersed in the frosting base. Rapid cooling can facilitatecrystallization of the shortening into a highly beta prime crystallineform. Rapid cooling may facilitate desired growth of beta prime tendingfat crystals, which stabilize small air cells and inhibit coalescence ofthe air cells. For example, immediately after homogenization the productmay be passed through a swept surface heat exchanger and cooled to lessthan 70 F (21 C). A suitable device for this step, referred to as a“Votator,” is described in U.S. Pat. No. Re. 21,406 to C. W. Vogt, Mar.19, 1940.

The cooled homogenized frosting base can subsequently be mixed withnitrogen gas 46 or another inert gas. The gas can be sparged into thevotated frosting base. Any conventional method can be used. For example,the gas can be forced through small orifices into the composition as thecomposition flows through a tube or vessel into a mixing chamber, whereuniform distribution occurs. Any conventional nontoxic, odorless,tasteless propellant, such as air, nitrogen, nitrous oxide, carbondioxide, and mixtures thereof can be used.

Process 10 can also include a step (50) of aerating or whipping thecooled, homogenized, frosting base from a native density to a density ofabout 0.75 to 0.95 g/cc. During aeration, the temperature of thefrosting base can be controlled by simultaneous cooling so that thefrosting product remains below about 32 C. (90 F) during the aerationstep. The cooling can offset heat generated in the frosting during theaeration step. Maintaining the temperature below 95 F (35 C) can beeffective to maintain the fat in a desired crystal state which, in turn,can reduce or minimizing air cell collapse upon extended storage. Apreferred target temperature may be 90 to 94 F (32 to 34 C).

The frosting ingredients (cooled homogenized frosting base) can beaerated from a native density of the of about 1.2 to about 1.4 grams percubic centimeter, to provide a finished low density frosting having adensity of from about 0.70 to 0.95 g/cc, preferably about 0.75 to 0.85g/cc. Even a stable low density frosting may exhibit some tendency tocoalesce as observed by a modest increase in density over extendedstorage times. Preferred low density frostings can be stored (e.g., at70 F) for weeks (2, 4, 6 weeks) or months (1, 2, 4 months) whilemaintaining a density in a range from 0.75 to 0.95 g/cc, e.g., fromabout 0.75 to about 0.90. Particularly preferred embodiments of the lowdensity frosting can also pass the Stir-Down Test after weeks or monthsof such storage, by having a density that does not fall below 0.94 gramsper cc, preferably not below 0.90 grams per cc, upon stir-down.

The aerated low density frosting can be packaged 60 in suitable airtight containers or packages (e.g., plastic tubs) for commercialdistribution and sale. In certain embodiments the packaging step caninclude a gentle, low shear packaging step with minimum piping to avoidcollapse of the frosting, and can occur within 15 minutes of aeration.

The preparation process can desirably exclude a step of handling (e.g.,pumping) the aerated frosting in a manner that substantially increasesthe density of the frosting, such as to a density of greater than 0.95grams per cubic centimeter. Pumping or other techniques that impartshear to the aerated product can result in weakening the low density aircell-containing structure. Excessive post-aeration shear may undesirablyresult in stirring the product down to its native (non-aerated) density.In preferred packaging methods, the product can be fed to a sealablehopper. Low pressure air (10 to 15 psig) can be supplied to the hopperfrom which the product is fed into tubs using air pressure rather thanpumping.

Examples

The following examples show fat materials processed according to stepsfor forming a low density frosting. As shown, various examples of totalfat ingredients that include palm oil-based shortening ingredient incombination with crystal-enhancing fat ingredient are useful to form alow density frosting, whereas the same palm oil-based shorteningingredient by itself (in the absence of the crystal-enhancing fatingredient) was not.

Three palm oil-based shortening ingredients were used in the examples:

Shortening 1

MDP: 37 to 41 degrees Celsius (98 to 106 degrees Fahrenheit).SFC from about 49 to 57 percent at 10 degrees C., from about 23 to 30percent at 20 degrees C., from about 6 to 13 percent at 30 degrees C.,up to about 4 percent at 40 degrees C.

Iodine Value 51-53.

Free fatty acid (oleic) not more than 0.05 weight percent.

Shortening 2

MDP: 39 to 44 degrees Celsius (102 to 111 degrees Fahrenheit).SFC from about 48 to 51 percent at 10 degrees C., from about 30 to 38percent at 20 degrees C., from about 10 to 18 percent at 30 degrees C.,up to about 8 percent at 40 degrees C.

Iodine Value 48-51.

Free fatty acid (oleic) not more than 0.05 weight percent.

Shortening 3

MDP: 40 to 60 degrees Celsius (104 to 115 degrees Fahrenheit).SFC from about 49 to 57 percent at 10 degrees C., from about 29 to 37percent at 20 degrees C., from about 11 to 19 percent at 30 degrees C.,from about 5 to 10 percent at 40 degrees C.Free fatty acid (oleic) not more than 0.05 weight percent.

Samples of each of the Shortenings 1, 2, and 3 were combined with twodifferent crystal-enhancing fat ingredients: Crystal-Enhancing FatIngredient 1, and Crystal-Enhancing Fat Ingredient 2:

Crystal-Enhancing Fat Ingredient 1 (#1)

This is a commercially available fully-hydrogenated soybean oil flakeproduct.

MDP 65.0 to 70.0 (Celsius)

I.V. 5 (maximum)Free fatty acids (0.10 percent) (maximum).

Crystal-Enhancing Fat Ingredient 2 (#2)

This is a commercially available blend of partially-hydrogenatedcottonseed and soybean oil, and fully-hydrogenated cottonseed andsoybean oil.

MDP 130 (Fahrenheit)

Free fatty acids (0.10 percent) (maximum).

Samples 1 through 9 were prepared from Shortenings 1, 2, and 3,Crystal-Enhancing Fat Ingredient 1, and Crystal-Enhancing Fat Ingredient2, as follows.

Samples 1, 4, and 7 are 100 percent Shortening 1, Shortening 2, orShortening 3, respectively.

Sample numbers 2, 5, and 8 include 14 percent of Crystal-Enhancing FatIngredient #1 (fully-hydrogenated soybean oil) and 86 percent ofShortening 1, Shortening 2, and Shortening 3, respectively.

Sample numbers 3, 6, and 9 include 14 percent of Crystal-Enhancing FatIngredient #2 (partially-hydrogenated cottonseed and soybean oil blend)and 86 percent of Shortening 1, Shortening 2, and Shortening 3,respectively.

Each Sample was used as the total fat ingredients of a low densityfrosting, along with other ingredients including sugar, emulsifier,water, etc., which were the same for the frosting made from each Sample.Each of the frostings was tested for density (D)(grams/cubiccentimeter), Stir-Down density (S.D.D.)(grams per centimeter), andviscosity (V) (percent torque), at 24 hours after preparation, 7 daysafter preparation, and 14 days after preparation. Results are in thefollowing table.

Shortening/ Crystal- Enhancing Fat 24 hr 7 Day 14 Day Ingredient D S.D.DV D S.D.D V D S.D.D V Sample Preferred ranges 0.78-.82 <0.9 >14 0.78-.82<0.9 >14 0.78-.82 <0.9 >14 1 1/n.a. 0.88 0.97  8.7 0.87 0.96 10.6 0.880.96 12.1 2 1/#1 0.8 0.82 18.7 0.79 0.83 21.2 0.8 0.85 25.4 3 1/#2 0.780.79 15.6 0.77 0.77 16.7 0.78 0.79 16.1 4 2/n.a. 0.78 0.91  8.8 0.8 0.910.6 0.78 0.91 10.6 5 2/#1 0.79 0.8 17.5 0.77 0.79 22.2 0.79 0.83 25.3 62/#2 0.79 0.8 16.4 0.78 0.78 18.4 0.78 0.79 20.1 7 3/n.a. 0.88  9 0.790.89 13 0.82 0.92 14 8 3/#1 0.79 0.82 17.7 0.79 0.82 29 9 3/#2 0.81 190.76 0.81 19 0.76 0.81 20

Viscosity

Viscosity is a measure of the degree of thickness or spreadability ofthe frosting. Viscosity relates directly to how the frosting functionswhen a consumer uses the frosting, such as by applying the frosting to acake. As specified herein viscosity is measured at 70 degreesFahrenheit, using a Brookfield DV-I viscometer and the following steps.

-   1. Place frosting sample (70 degrees F.) in a cup.-   2. Lower the clean and dry spindle (F-T-Bart) until it is just above    the surface of the frosting. (For cooked frosting, use the F-C-Bar.)-   3. Turn on the viscometer motor. With the spindle rotating (@20 RPM)    make sure the L.E.D. display reads “00.0.”-   4. Turn on the Helipath motor to being the downward movement of the    spindle.-   5. As soon as the cross bar breaks the surface of the frosting,    count 6 revolutions and note the reading on the L.E.D. display (to    the nearest 0.5).

Desired viscosities (expressed in units of percent torque) of a lowdensity frosting as described herein can be in a range from 18 to 30,e.g., from 18 to 25, or from 18 to 22 percent torque (wherein percenttorque×5000=viscosity in centipoise).

Stability as Measured by Stir-Down Test

The Stir-Down Test measures stability of a frosting by comparing adensity measurement of a frosting sample to a density of the samefrosting after the frosting has been stirred in a manner that has thepotential to substantially increase the density of the frosting. Anincreased density of the frosting is an indication of instability of thelow density frosting.

Apparatus:

Density cup—a 222-223 cubic centimeter (cc), 90 gram cup, 4.2 cm. high,undented.

Metal spatula—a stainless steel blade approximately 8 inches in lengthand 1¼ to 1½ inches wide.

Scale—an accurate scale measuring in grams.

Procedure: Collect 2 samples (340 grams each) of a frosting for testing:One “line sample” from preparation of the frosting, and one sample (fromthe same source) to be set aside as a “24 hour sample” to be testedafter being held for 24 hours at 70 F.

Line Sample Test

Fill the clean, dry, room temperature cup slightly over the brim withfrosting (70 F) from the line sample, soon after taking the sample frompreparation.

Tap the cup firmly on the bench to eliminate air pockets.

Remove excess frosting by passing the spatula's smooth, flat edge acrossthe surface of the cup at about a 45 degree angle starting from themiddle of the cup, scrape both halves off.

Zero the scale and place the filled cup on the scale; record thecombined weight of the cup and frosting.

Determine the density of the frosting based on the known volume of thecup and the measured weight of the frosting sample, less the 90 gramweight of the cup.

Record the value as frosting density.

Return the frosting sample to the tub; stir the sample 10 times; scrapethe perimeter of the tub; stir 10 more times, scrape again, stir 10 moretimes for a total of 30 stirs before filling the density cup again.Weigh the cup and determine the density of the stirred frosting based onthe known volume of the cup and the measured weight of the cup andfrosting sample, less the 90 gram weight of the cup. This is thestir-down density.

A stir-down density result of less than 0.94 g/cc, preferably less than0.90 g/cc, is preferred. A Stir-Down Density that is above 0.94 g/cc isconsidered to fail the test. Preferred stir-down density values can bebelow 90 g/cc, e.g., preferably from about 0.72 to about 0.88, e.g.,from about 0.76 to about 0.82 g/cc.

24 Hour Sample Test

After holding the 24 hour sample for 24 hours at 70 F, test the frostingaccording to the same steps listed above. A stir-down density result (ofthe 24 h sample) of less than 0.94 g/cc, preferably less than 0.90 g/cc,is preferred. Above these 0.94 g/cc is considered to fail the test.Preferred stir-down density values can be below 90 g/cc, e.g.,preferably from about 0.72 to about 0.88, e.g., from about 0.76 to about0.82 g/cc.

Rate of Crystallization of Samples 1 through 9

The Rate of Crystallization (ROC) of each fat samples 1 through 9 wasmeasured by shock-cooling a sample of each melted fat while measuringthe percent solids with time progression. Rate of crystallization of afat is a measure of the changing amount of crystallized solids containedin a fat sample, over a period of time at which the temperature of thesample is reduced under controlled conditions. Rate of crystallizationcan be measured using standard Nuclear Magnetic Resonance (NMR) testingequipment and methods, such as the minispec mp 20 NMR by Bruker.

1. The NMR instrument must be powered on, calibrated, and warmed up andoperational.2. Melt a solid sample of fat (sufficient for step 3) using a microwaveoven or stove top.3. Pipette from melted fat sample into 20 individual 180 millimeter(mm)×10 mm glass NMR tubes (fill glass tube to an effective level, suchas to a height of 40 millimeter).4. Place these 20 tubes containing the melted fat into a 60 C water bathto temper for approximately 15 minutes.5. After tempering to 60 C for 15 minutes, move glass tubes in sets offour each into individual tempering baths that are set to the followingconditions:

-   -   a. 4 tubes (all at one time) to 0 degrees C. Start timer.        Continue to add tubes to 0 degree water bath.    -   b. 4 tubes (all at one time) to 0 degrees C.    -   c. 4 tubes (all at one time) to 0 degrees C.    -   d. 4 tubes (all at one time) to 0 degrees C.    -   e. 4 tubes (all at one time) to 0 degrees C. All 20 tubes are in        the bath before the timer reaches 30 seconds.        6. When timer count is at 30 seconds, remove the first tube from        bath and place in the NMR instrument and take reading, which        measures percent solid of the sample. It takes 10 to 15 seconds        for the NMR to register a reading.        7. When the timer count is at 60 seconds, take the next tube        from the 0 degree C. bath and place in the NMR instrument and        obtain the second data point (percent solids of the sample).        8. The subsequent time intervals at which to pull samples from        the 0 degree C. bath and place in the NMR follow the pattern        outlined here:

1′ 30″ 2′ 00″ 2′ 35″ 3′ 05″ 3′ 35″ 4′ 05″ 4′ 40″ 5′ 10″ 5′ 40″ 6′ 10″ 6′45″ 7′ 15″ 7′ 45″ 8′ 15″ 8′ 50″ 9′ 20″ 9′ 50″ 10′ 20″ 9. Record percent solids reading of all 20 samples, and plot the percentsolids versus seconds to obtain the Rate of Crystallization profile.

ROC profiles for samples 1, 2, 3, 4, 5, 6, 7, 8, and 9, are shown atFIGS. 1, 2, and 3. These figures also show ROC of a Control fat of 100percent of a partially-hydrogenated blend of soybean oil (85 to 90weight percent) and cottonseed oil (10 to 15 weight percent); an IVvalue of from 65 to 75; MDP of from 105 F to 120 F (preferred about 110F); a trans fat content of from 25 to 35 weight percent, and containingno amount of crystal-enhancing fat ingredient as described. The SFCprofile of the control includes the following solid fat contentreadings: @50 Deg F: 51-59; @70 Deg F: 30-38; @80 Deg F: 22-28; @92 DegF: 13-18; @104 Deg F: 6-11).

Samples 1 through 9 were tested for SFC (at temperatures of 10 C, 21.1C, 26.7 C, 33.3 C, and 40 C) and MDP, with results in the followingtable.

Sample 10 (C.) 21.1 (C.) 26.7 (C.) 33.3 (C.) 40 (C.) MDP 1 51.5 19.810.6 5.2 2.1 38.5 3 59.6 32.0 19.5 10.0 2.5 41.7 2 62.3 41.4 30.9 21.313.7 49.2 4 56.5 28.9 18.3 11.2 6.4 46.3 6 64.2 38.4 25.7 14.8 5.8 43.65 65.8 45.8 35.6 25.2 16.8 49.8 7 51.9 28.0 18.4 10.2 4.2 42.1 9 60.437.2 26.2 14.8 5.4 44 8 63.2 43.9 35.4 25.6 16.7 50.3

1. A low density aerated frosting comprising: from 50 to 85 weightpercent sweetening agent based on total weight frosting; from 15 to 30weight percent total fat ingredients based on total weight frosting, thetotal fat ingredients exhibiting a rate of crystallization profilehaving a percent solid fat measurement of 22 to 35 percent at 2.5minutes, 32 to 50 percent at 5 minutes, 39 to 52 percent at 7.5 minutes,and 39 to 55 percent at 10 minutes, and comprising: at least 50 weightpercent non-hydrogenated palm oil-based shortening ingredient, and fromabout 7 to about 25 weight percent fully-hydrogenated crystal-enhancingfat ingredient, based on weight total fat ingredients; from about 0.5 toabout 5 weight percent emulsifier based on total weight frosting; andfrom 10 to 20 weight percent water based on total weight frosting;wherein the aerated frosting has a density in a range from 0.75 to 0.90grams per cubic centimeter.
 2. A frosting of claim 1 wherein thefully-hydrogenated crystal-enhancing fat ingredient has an Iodine Valuethat is not greater than
 5. 3. A frosting of claim 1 wherein thefully-hydrogenated crystal-enhancing fat ingredient is derived from atropical source.
 4. A frosting of claim 1 wherein the total fatingredients include a room temperature solid interesterified fat.
 5. Afrosting of claim 1 wherein the total fat ingredients includeinteresterified palm oil.
 6. A frosting of claim 1 wherein the total fatingredients exhibit a rate of crystallization profile having a percentsolid fat measurement of at least 23 percent at 2.5 minutes.
 7. Afrosting of claim 1 wherein the frosting exhibits a Stir-Down Density ofless than 0.94 grams per cubic centimeter.
 8. A frosting of claim 1wherein the frosting exhibits a Stir-Down Density in a range from about0.75 to about 0.90 grams per cubic centimeter.
 9. A frosting of claim 1,wherein the total fats ingredients comprise 7 to 20 weight percentfully-hydrogenated crystal-enhancing fat ingredient, based on weighttotal fat ingredients.
 10. A frosting of claim 1, including from 0.5 toabout 4 weight percent emulsifier based on total weight frosting.
 11. Afrosting of claim 1, wherein the emulsifier comprises a monoglyceride.12. A frosting of claim 1, wherein the emulsifier comprises a mono- anddiglyceride blend.
 13. A frosting of claim 1, wherein the frostingcontains less than 2 weight percent trans fat based on total weightfrosting.
 14. A frosting of claim 1, wherein the frosting contains fromabout 20 to about 28 weight percent palm oil-based shortening ingredientbased on total weight frosting.